The module aims at providing the basic knowledge of the manufacturing processes for metal sheet parts,plastic and composite components in the automotive sector. Starting from the 3D CAD model of the part, all the steps that lead to the design and fabrication of production tooling are analysed by a Concurrent Engineering approach integrating modern CAD/CAM/CAE techniques.

The student is expected to learn a basics knowledge of main industrial processes for metal sheet parts, plastic and composite components manufacturing. Computer aided time compression techniques in product/process design will be applied in the practices. The student will acquire the ability to design, by means of a CAD/CAE simulation software, a simple tool for the fabrication of a metal sheet part and a mold for an injection molding product.

The student who follows the subject should have knowledge of Mechanical Drawing, and Technology of Metallic Materials and Manufacturing Technology. Students must be familiar with the use of the Personal Computer.

Introduction (3h) - Resume of car body frames, structures and body components - Overview of metal materials for the automotive body - Polymers, their properties and examples of metal replacement Injection moulding process (18h) - Process description - Rheological behaviour of plastics - Analysis of the flow of the plastic melt during mould filling - Characteristics and components of an injection moulding machine - Design principles of a mould for injection moulding - The role of simulation in mould design - Optimization of moulding parameters - Photoetching and other finishing processes - Co-injection and multimaterial moulding - Gas assisted injection moulding Manufacturing processes for sheet metal parts (9h) - General considerations - Blanking and piercing operations - Bending operations - Forming operations - Forming Limit Diagram - Hydroforming operations Composite manufacturing (6h) - General introduction about composites - Manufacturing processes for polymers - Current trends and recent applications of composites in the automotive sector - Concepts of lightweight design and innovative technologies/materials Training about the simulation of sheet metal forming of an automotive part (12h). Training about the optimization of the injection moulding process and its parameters for the production of an automotive plastic part (12h).

Lectures on the course topics are held in the teaching rooms of Mirafiori Campus. Practical activities and training sessions take place either in the PC laboratory or, if students are using their own laptops for simulation work, in the teaching rooms of Mirafiori Campus. Each student will be provided with a license for the simulation software packages. The first part of practical activities focuses on process simulation for sheet metal forming. The second part of the practical activities focuses on process simulation and the optimization of molding conditions using specialized CAE software for the injection molding of plastic components. The start of each practical session will be dedicated to a step-by-step tutorial on developing software simulations. The remaining time will be devoted to the development of a small projects, carried out under the supervision of the professor.

PowerPoint slides presented during the lectures will be provided on the course website. The following books are suggested, but not strictly required: -J. Lerma Valero, "Plastics Injection Molding", Hanser. -R. Dangel, "Injection Moulds for Beginners", Hanser. -H. Zhou, "Computer Modeling for Injection Molding: Simulation, Optimization, and Control", Wiley. -I. Suchy, "Handbook of die design", McGraw-Hill. -H. Gastrow, "130 proven mold design", 4th Edition, Peter Unger Ed.

Slides; Dispense; Esercitazioni di laboratorio risolte; Strumenti di simulazione;

E' possibile sostenere l?esame in anticipo rispetto all?acquisizione della frequenza

Modalita di esame: Prova scritta (in aula); Elaborato progettuale in gruppo;

Exam: Written test; Group project;

... The final exam is composed of two parts: - a written exam about the topics covered during the lectures; - the evaluation of the technical report of the training. The written exam consists of five or six open questions and it is closed books and closed slides or notes. The duration of the written exam is about 2 hours. The written exam is aimed at the evaluation of student's knowledge about: 1) Concepts of lightweight design and innovative technologies/materials; 2) Polymers and their main properties; 3) Injection moulding process and design principles; 4) Injection moulding machine and its working cycle; 5) Manufacturing processes for sheet metal parts; 6) Manufacturing processes for composites. The technical report about the project that was developed in group during the training is compulsory and it must be delivered at least a week before the beginning of the exam session. The technical report is aimed at the evaluation of student expertise through team working in the design and optimization of a manufacturing process for an automotive component. The written exam contributes to the definition of the final grade for a maximum of 24 points out of 30. The grade is integrated by the evaluation of the technical report about course practices for a maximum of 6 additional points. In case of maximum grade (30 over 30), the honor is attributed at the discretion of the professor.

Gli studenti e le studentesse con disabilita o con Disturbi Specifici di Apprendimento (DSA), oltre alla segnalazione tramite procedura informatizzata, sono invitati a comunicare anche direttamente al/la docente titolare dell'insegnamento, con un preavviso non inferiore ad una settimana dall'avvio della sessione d'esame, gli strumenti compensativi concordati con l'Unita Special Needs, al fine di permettere al/la docente la declinazione piu idonea in riferimento alla specifica tipologia di esame.